Transformers - GE Grid Solutions

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gTransformersThree Phase up to 1500MVAwith PrimaryPlusTMPre-engineered solution set that digitizes XD GE primary equipment and provides factoryinstalled and configured protection, monitoring, diagnostics and communications.GEDigital Energy

TransformersCrane Capacity of 800T at Port of Export800kV Converter Transformer in Xiangjiaba, ShanghaiRevolutionizing the High Voltage Transformer SegmentFor over a century, utilities around the world have relied on GE products andservices to increase power system reliability and improve grid resiliency andresponsiveness. As a global leader in grid infrastructure products and services,GE supports a broad set of utility applications ranging from transmission andsubstation automation to distribution networks and smart metering, enablinggreater safety, connectivity and increased security.Through an alliance with XD Electric , GE has extended its portfolio to includehigh and ultra high-voltage power equipment, supporting the highesttransmission voltage levels in the world.XD Electric is one of the world’s largest primary equipment manufacturersdedicated to the research, application and development of high and ultra highvoltage power transmission equipment. XD Electric is also one of the premierehigh-voltage transformer manufacturers in China with world-class designcapability and a significant installed base for ultra high-voltage (UHV) ACand DC technologies. Their designs are well established and XD has a largeinstalled base for selected power transformer and reactor technologies.XD GE provides a suite of transformer products that offer a wide range ofvoltages and capacities to support the highest voltage levels available aroundthe world. The XD GE products are designed to meet a variety of customer2applications including generator step-up (GSU) transformers, substation stepdown transformers, auto transformers, HVDC converter transformers, rectifiertransformers, arc furnace transformers, railway traction transformers, shuntreactors, phase shifting transformers and resin cast coil dry type.Designed to Optimize PerformanceWith units operating in some of the most demanding electrical environmentsaround the world, XD GE designs and delivers technology solutions thatprovide among the highest level of performance and reliability to meetcustomer’s operating requirements. XD GE’s large technical staff of subjectmatter experts in various facets of engineering have developed an advanced,integrated and proven design and manufacturing technology for its entiretransformer portfolio of products.XD GE designs and delivers technology solutions that exceed customers’critical and demanding performance and reliability requirements.These advanced systems have produced first to market and innovativeproducts including the first 1000kV, 1000MVA dual-column ultra high-voltageauto transformer in the world.GEDigitalEnergy.com

TransformersKey BenefitsThe transformer and reactors development efforts areconsistently focused on maximizing performance to: Decrease electrical stress in the insulation structures andhelp prevent of partial discharge initiation Improve winding impulse voltage distribution characteristicswith in-depth studies and performance analysis Reduce leakage flux density control and stray loss Control over heating of the high current leads by redesigningthe structure and lead arrangement Improve the operational reliability of transformers byincreasing the short circuit withstand strength of thewindings Minimize the effects of DC biasing on the transformer coreby analyzing currently used methods Decreased noise levels, down to 65dB, with advanced corestacking technology Minimize oil flow to reduce the temperature rise of windings Improve tank design to meet and/or exceed transportationstrength requirementsPrimary PlusAdvanced Technology PlatformXD GE has developed an advanced 3D Computer Aided Engineering (CAE)system for 3D design of transformers, 3D assembly simulation, and quickgeneration of engineering drawings. The 3D CAE system performs designoptimization, analysis of the electrical and electromagnetic field and thermaldesign. This ensures high reliability in our transformers and shunt reactors.The 3D CAE system has been used in the development and manufacturing of alltransformers, including several key new products such as: 750kV and 1,000kV transformers and shunt reactors 500kV, 50 MVAR and 750kV, 140MVAR adjustableshunt reactor Converter transformers and smoothing reactor for the 500kV and 800kV DC transmission projectXD GE offers Primary Plus on all its primary equipment.Primary Plus is a pre-engineered solution set that providesutilities with a means to reduce the time and labor associatedwith substation construction and expansion, while at thesame time utilizing technologies and methodologies familiarto existing resources.XD GE’s factory installed and configured solutions include: Digitized primary equipment by replacing labor-intensive,individually terminated copper wires with standardizedphysical interfaces and open digital communications Electrical protection systems optimized for the equipmentand application to monitor and react to fault conditions Monitoring and diagnostics of transformers to predictproblems and proactively manage performance Highly secure and ruggedized communication networkequipment including industrial strength wireless, fiber opticmultiplexers, and Ethernet switches for an advanced andreliable communications infrastructure

TransformersPower and Auto Transformers, and ReactorsPower and Auto TransformersXD GE offers a broad line of power transformers with three phase ratingsfrom 20 to 1500 MVA, voltage ratings from 69 up to 765kV, and single phaseratings to 1000 MVA, 1000KV. Three phase auto transformers are availablewith ratings to 765kV, 1500 MVA, and single phase auto transformers to1000kV, 1500 MVA.The GSU transformer is a key technology for electric power generation andpower transmission. The generator transformer, designed and manufacturedby XD GE, fully complies with the requirements for power generation islandswith excellent performance and exceptional reliability for low loss, low noise,low partial discharge and high short-circuit withstand.The size and performance of the power transformers available from XD GEare world class, such as the first 1,000MVA / 500kV ASA high impedanceautotransformer installed in China the first of its kind.transformer and the starting/spare transformer used at the power station.The voltage class covers a range from 35kV to 500kV with a range of thecapacity from 31.5 MVA to 130 MVA.The structure will be designed to the impedence specified by the customer,providing a high capability to withstand short circuit force and to supplyreliable power.ReactorsShunt reactors are core to XD GE’s portfolio, with more than 600 unitsinstalled, at 500kV or higher, in various regions around the world. As partof XD GE’s ongoing initiatives for continual product improvement, extensiveresearch on shunt reactors has resulted in an improved core design.These improvements have reduced the total losses to less than 100kW,XD GE provides a broad range of products that align with the many types ofthermal power and water power sets, including 200MMW, 250MW, 300MWand 600MW configurations.To meet specific requirements, customers have the flexibility to customizetheir transformers. A range of options are available, including: A variety of de-energized and on-load tap changers from approvedsuppliers. Control and monitoring systems are available for the on-loadtap changers that allow for parallel operation and remote control A wide range of monitoring and diagnostic options are availableincluding bushing monitoring, dissolved gas analysis, hot spot windingtemperature, oil hot spot, and both UHF and ultrasonic partial discharge Gauges are available from a variety of suppliers. Available optionsinclude analog gauges as well as digital gauges that work with remotemonitoring systems Pressure relief devices are available with or without an oil flow directorthat can be routed toward the bottom of the tank Buchholz relays are available as well as fire extinguishing systemsthat release nitrogen to the inside of the tank and a shut off valve whenan event is detected Typical oil preservation systems used for power transformers are alsoavailable. A corrugated stainless steel conservator that goes up anddown and requires no breather or air bag is also available Cooling systems, utilizing panel radiators, fans, oil pumps and coolers areavailable from approved vendors Water cooling is available for rectifier transformers and hydro-powerapplications. Radiators can be controlled to turn on sequentially withincreasing temperaturePower Generation Double Split Transformer DesignTo meet and exceed the transformer requirements for power generation,XD GE specially designs and manufacturers low voltage radial double splittransformers. This design enhances the ability of short circuit withstand of the4610 MVA, 1700kV Testing TransformerGEDigitalEnergy.com

TransformersRectifier Transformerssignificantly reducing partial overheating. Additionally, there have beenreductions in the core noise and vibration, enabling high levels of reliability.Smoothing reactors, used in HVDC systems, are available with voltages upto 800kV DC and have been developed in both liquid filled and dry typedesigns. The liquid filled reactors can be customized with many of the optionsavailable for power transformers.Single phase shunt reactors are available in voltage ratings ranging from35kV to 1000kV with MVAr ratings of 20, 30, 40, 50, 60, 70, 100, 140, 240, and320 MVAr. Three phase shunt reactors are available in voltage ratings from 35to 400kV, with MVA ratings of 20, 30, 40, 50, 60, 80, and 100 MVAr. Single phaseshunt reactors are available with AC control of the shunt reactance or with atertiary winding to supply power in the 150 to 250kVA range for installationsin remote locations where local power is not available.Rectifier TransformersTransformers for use in industrial applications must be designed to withstandsevere and extreme operating and environmental conditions. Huge currentsneed to be supplied to arc and smelting furnaces for aluminum, zinc, and chlorineprocessing. They must operate through cyclic loads, high thermal stress, and overvoltage and current conditions caused by short circuits in the furnace.XD GE delivers advanced and ruggedized rectifier transformers that meetcustomers unique operating and environmental requirements.Delivering these advanced and ruggedized transformers is a unique niche forXD GE. Rectifier transformers can be supplied with ratings ranging from 35kVto 220kV, and up to 140MVA, some of the largest in the world.240 MVAr, 1000kV Shunt ReactorVarious transformer configurations are available, including: On-load or off-load tap changersThree phase bridge-type rectifierDouble Delta-star three phase, five-leg rectifier transformerCooling options including ONAN, ONAF, OFWF, OFAF, ODAFKey CharacteristicsThe chart below is an overview of the characteristics for a sampling of largerectifier transformer:TypeCapacity(MVA)DC Voltage(V)DC Current(A)Numberof 6.2MVA/330kV13613002x4400012110 MVA, 220kV Rectifier Transformer with OLTCGEDigitalEnergy.com5

TransformersHVDC Converter and Arc Furnace TransformersHVDC Converter TransformersXD GE has designed the HVDC converter transformer to the maximum 800kVvoltage level and has produced a large number of these transformers. Thesehave been developed to support projects from 50kV HVDC back-to-backconverter stations up to 800kV HVDC transmission projects.XD GE has a large manufacturing base for complete HVDC equipment inChina. Since the 1980s, the XD Group has been involved in all twenty three(23) completed and ongoing HVDC transmission engineering projects in China.Converter TransformerManufacturing Scope for 50kV - 800kV Voltage Level: System research and design, DC system simulation Thyristor valves Converter transformer, smoothing reactors and filters Shunt capacitor, equalizing capacitor for thyristor valves301 MVA, 500kV Converter Transformer for 50kV DC Back-to-Back Converter Station321 MVA, 500kV Converter Transformerfor 800kV HVDCArc Furnace TransformersXD GE has developed the technology to produce a range of arc furnacetransformers including arc steel-smelting furnace transformers, ladle refinedfurnace transformers, and large ore arc furnace transformers. XD GE arcfurnace transformers are available in AC and DC supply, with capacities upto 200 MVA with 35kV single-core design, up to 160 MVA with series voltageregulation, and up to 100 MVA with a primary voltage of 110kV.90 MVA Arc Furnace Transformer6GEDigitalEnergy.com

TransformersRailway Traction and Cast Coil TransformersRailway Traction TransformersThe three phase/two phase impedance matching balance connection tractiontransformer for electrification of railways is suited for the operation conditionof frequent short-circuits, short periods of severe overloads, and asymmetricalloading of the three phases.This new type of traction transformer is greatly improved both in structureand performance.XD GE produces a variety of railway traction transformers including: Impedance matched balance traction transformers Traction transformers with Vv connectionTraction TransformerCast Coil TransformersThe cast coil transformer is a low-noise, low-loss, cast resin dry-typetransformer. The high-voltage (HV) winding with copper conductors and thelow-voltage (LV) winding with either copper conductors or copper sheet arewound and reinforced by glass-fiber and then cast with resin under vacuum.Characteristics of Cast Coil Transformers:Special Designs:Though standard cast resin dry type transformers can meet the demandsof most applications, special designs can be developed for single phasetransformers, isolation transformers, rectifier transformers, groundingtransformers and transformers with special tapping arrangements. Windings have high mechanical strength and no partial discharge Epoxy resin and insulating materials used for windings are nonflammable, will not burn from an electric arc, and no toxic gases will begiven off when the resin is burned Windings will not absorb moisture and a special anti-rust protectivecoating seals the core and frame. Operates under one-hundred percent relative humidity and other severeambient conditions Ability to switch on the device without pre-drying or long periods of serviceinterruptions Excellent short-circuit and lighting impulse strengthCast Coil vvvf Transformer20 MVA, 35kV Cast CoilTransformerTechnical Specifications: Cooled naturally by air (AN) and forced air cooling (AF) provided as anoption to improve overload capacityVoltage level10-35kVPower capacity30-20000kVA Smaller dimensions, less weight, and space savingType of voltage regulationoff-circuit or on-load Oil drainage pits and fire extinguishing devices not required foroperationTapping range5%, 2 2.5% (or as requested)Frequency50Hz or 60HzPhasesThree phaseConnection symbol:Y yno; D yn11 (or as requested)Maximum temperature rise:100 CCooling methodAN or AFGEDigitalEnergy.com7

TransformersInnovative Facilities and Rigorous Quality ProcessesXD GE’s technology portfolio is built in state-of-the-art manufacturing andtesting facilities with robust quality processes which provide customers withproducts that meet the critical and demanding reliability and environmentalchallenges of transmission applications.Manufacturing ExcellenceXD GE manages 4 state-of-the art manufacturing facilities with capabilitiesto design a full range of transformers and shunt reactors with operatingvoltages up to 1100kV. Key highlights include: ISO 9001 certified facilities Core type technology Annual manufacturing capacity of 200,000 MVAAdvanced Test FacilitiesXIHARI , the Xi’an High Voltage Apparatus Research Institute, is an integralpart of the XD GE alliance. XIHARI has extensive testing capabilities at itsfacility sites, which include a: High Power Laboratory, High Voltage Laboratory,Artificial Climate Laboratory, EMC Laboratory, and an Operational Test Circuitfor HVDC Thyristor Valves.The testing facility for XD GE transformers is currently the largest testing hall inAsia, measuring over 40,000 square feet and having a ceiling height of nearly160 feet. It meets the requirements of ISO/IEC 17025 and boasts some of thelargest test equipment in the world, creating capacity to test transformers aslarge as 1100kV/1500MVA, 1100kV/360Mvar shunt reactors, 800kV/380MVAconverter transformers, and 800kV/4500A smoothing reactors.Dielectric tests can be performed for AC transformers and shunt reactorsrated up to 1100kV AC and on HVDC convertor transformers rated up to 800kV DC. The transformer facilities also have impulse generators rated at4800kV/720kJ, power frequency test transformers rated to 1800kV/2A, 4200kVlightning impulse chopping device, DC voltage generators, and high-voltagecapacitors for thermal testing, impedance testing and load loss testing atmaximum ratings. 400 ton bridge crane, 400 ton air cushions 400 kW/9 m vapor phase drying ovens 150 ton stacking tables 40 ton vertical winding machines Isolated clean rooms for winding and assembling 230kV Direct seaport access for transformers up to 800 tonsExceptional QualityA focus on quality is an ongoing strategic initiative for XD GE and that isevidenced throughout the manufacturing environment. The quality processbegins with an incoming inspection of all materials to ensure the best possibleinputs before manufacturing begins.Throughout the production and assembly process, there are multiplecheckpoints, including both visual inspections as well as stopped flow.Inspections are all perfomed to documented test plans. The productionfacilities follow strict non-conforming procedures to identify, control andavoid the use and delivery of non-conforming products. Each productionfacility has developed strict environmental standards, including controls ofcleanliness, temperature and humidity. Controls are in place to monitor andmanage to the established standards.In addition, XD GE has a dedicated measurement and inspection departmentwith a certified full time inspector in each of its manufacturing sites.The measurement and inspection department provides a secondary crossinspection for all work in process, as well as finished products, ensuring a highlevel of quality is achieved throughout the manufacturing process. First PassYield and Cost of Quality data is maintained and analyzed, per product family, inorder to drive continual product and process improvements and higherproduct reliability.From raw materials acquisition and inspection to finished product, XD GE’stransformers and shunt reactors are designed to meet rigid quality processesso the installed product provides the highest level of reliability.8GEDigitalEnergy.com

TransformersSupport and ServiceGlobal Project Engineering ServicesXD GE is dedicated to helping its customers reach their system objectivesand provides a suite of professional services to assist in the successfuldeployment and maintenance of XD GE products and solutions. From designand implementation to post-sales support, a team of technical and businessexperts are available to help customers effectively use the capabilities andproduct domain knowledge that are available from XD GE.This support infrastructure covers the entire life cycle of the product. From thecoordination of transportation logistics to the completion of site acceptancetesting and warranty service, the highly qualified XD GE team is availablethroughout the implementation.To ensure a high quality of service to meet the needs of each uniqueap

applications including generator step-up (GSU) transformers, substation step-down transformers, auto transformers, HVDC converter transformers, rectifier transformers, arc furnace transformers, railway traction transformers, shunt reactors, phase shifting transformers and r

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